Quality
assurance

Quality assurance develops everything related to risk management at the company, among other issues. Under a precautionary approach, an evaluation of the company's context is developed, called "Context Matrix", which shows the annual evolution of the objectives that are normally assessed on a long-term basis. As an output, a SWOT Analysis (Strengths, Weaknesses, Opportunities, Threats and Strengths) is performed, which includes both the internal and external perspectives.

Risk management is carried out through Aciturri's Business Continuity Plan.

The company released its first Business Continuity procedure, PSC-1003, in January 2018. This procedure, is based on the ISO 22301-2012 international standard. Based on this procedure, a preliminary analysis is made of the different threats and their consequences, especially in Aeroengines.

Risk management is carried out through Aciturri's Business Continuity Plan.

From 2021 to 2022, a business continuity methodology has been defined, which has ended with a modification of the PSC-1003 procedure, in accordance with ISO 22301-2019 and the defined way of working.

The Quality First program has brought about a change in people's mentality and in the way they approach problems.

The highlight of this new method is the use of tools already existing in the company, such as risk analysis. The objective is to calculate and keep the business continuity plans up to date with tools that are already in use in the organization.

Within this regulation and in the implementation, operational risks are differentiated from project risks and company risks, the so-called Business Continuity risks. An example of the implementation of these procedures has been the deployment of risks in MS Teams® panels of the Operations Management, the risk management of new projects and the finalization of the continuity plans for the Aeroengines and Aerostructures businesses (except for the assembly part, which will be completed in 2023).

In order to understand how this implementation has been carried out, it is important to highlight the definition of Business Continuity Plan (BCP) and how it is understood at Aciturri: the BCP is a documented method that includes the required instructions for the company to respond, in the event of a disruption, to recover as soon as possible its deliveries to the customer.

Along with the BCP definition, it was decided which was the objective of the deployment project, where it was going to be deployed, the method to be used and who had to be involved in each area:

  • What (Continuity Plan Goal): To continue delivery to the customer when a disruption arises.
  • Where (critical areas to be considered): Should be deployed throughout the company materialized by sites and considering facilities, industrial means, supply chain and IT.
  • How (Method): A pilot project is launched in Composite plants to once finished and with lessons learned, deploy to the rest of the organization.
  • Who: The MFT of Management is divided into the different MFT's that will participate in each of the sites. These MFT's are composed by top level of the organization.

The BCP process starts with the definition of critical areas in the organization (to support the delivery of products and services), and then defines which key areas / programs should be included in the BCP analysis. More specifically, an analysis is made of all systems, machines, equipment and people that will be involved in the BCP, to then assess the risks and establish an action plan to achieve the objective (RTO, recovery time, less than MTPD, maximum acceptable downtime).

Finally, with all the information gathered, the Business Continuity Plan is described for each technology. In 2022, the deployment has been carried out for Aeroengines and Metallics, during 2023 it will be carried out for Assembly.

These plans have been developed by multifunctional units, with the presence of teams from Operations, Supply Chain, Technical Services, People, Safety and Environment and Systems, and have been led by Quality. As a result of these plans, actions have been taken such as the validation of FPQ's and work orders for detailed parts for which we are the sole source in two of our sites, or the launching of polyvalence analyses between roles or positions in different work centers.

The Quality area has continued to work on compliance with contractual requirements and those linked to existing certifications, both those related to ISO, EN and other standards, as well as those of customers, civil aviation and defense authorities.

Aciturri has certifications under ISO 9001 and EN9100 for all sites, in addition to being a POA organization according to EASA21G in the Aeroestructures plants (except for Getafe one), EN9110 for the Assembly facility, from which service is provided at the customer's facilities, ISO 17025 for calibrations performed at the Tres Cantos site, PECAL 2110/ PECAL 2310 for Tres Cantos (manufacturing and design/development), Ayuelas and Orón.

In 2022, the Boecillo facility obtained EN9120 certification, which joins the Berantevilla logistic plant, which obtained it in 2021. This certification allows the company to have the capacity to distribute materials.

The company also has the required NADCAP certifications, according to the technology and processes carried out in each facility, having added during 2022 the NADCAP certification in assembly for the Boecillo, in addition to Ayuelas, which already had it.

These certifications ensure strict compliance with current regulations and legislation, and the traceability of each and every one of the products, recording the materials used and the people involved in their manufacture and assembly, as well as the certifications of the processes that support them. The use and maintainability of these are determined by design reviews, first articles and official certification tests. These are relevant issues for customers, civil and military aeronautical authorities, subcontractors, service companies operating in the company's facilities and employees themselves, according to the context and stakeholder matrix prepared by the area itself. Appropriate management of all this ensures response times, adaptation to the customer's requirements and any legal changes that may occur, and monitoring of subcontractors.

The company also has the required NADCAP certifications, according to the technology and processes carried out in each facility.

During 2022, progress continued to be made in the Quality First initiative, an improvement project launched in 2021, whose objective is to enhance the quality perceived by the customer and to reach product quality standards that will enable the company to establish itself as a benchmark in the sector.

This year, Quality First has been deployed in its containment stage and with the "Zero Escapes" claim, we have been able to achieve, first of all, no critical escapes in customer's side, reducing by 40% the average number of discrepancy reports for minor open events at reception in comparison between the first and second half of the year. Customer recognition has been achieved at performance meetings, due not only to the improvement in perceived quality, but also in terms of analysis, depth of root cause analysis and criteria convergence.

The development of the Quality First program has prompted a change in people's mindset and in the way they approach problems. In terms of objective data, the KPIs by which the project can be measured are:

QSR´s

attributable to Aciturri = 0, fulfilling the objective

Number of DR's

There has been a reduction in the number of pieces affected by DRs (Discrepancy Report) and in the number of DRs received.

Criticality of DR's

There is no longer recurrency. At the December 2022 Cross Program meeting, congratulations are received from the client for this drastic decrease in problems and rejections at their logistic reception.

Concessions processed

Fewer defects are also generated internally due to the use of cause analysis tools, thus exceeding the 30% reduction target for concessions with some clients.

Parts affected by DRs and quantities of DRs breakdown

Average: 26

All products placed on the market by Aciturri (100%) are carefully monitored and evaluated for their compliance with these contractual requirements, the standards that support the applicable certifications and the legal regulations in force, as well as in terms of safety, a critical aspect for the sector.

In 2022, there are no evidence of any cases of non-compliance with regulations or voluntary codes relating to the health and safety impacts of products and services.

The products labeled by Aciturri are not required to include details of components or handling instructions for their safety use. This information for handling and subsequent integration is contained in the drawings.

The certificate of conformity issued and signed by Aciturri indicates the part number of sale, including identification data with which the components and people involved in its manufacture can be traced. On the other hand, this certificate ensures that the parts are newly manufactured and some of them are audited by AESA to evaluate this certificate issuance.

During 2022, we have continued with the process established in 2021, whereby 100% of the MDF substances contained in each part number were transferred to one of the main customers. Due to the importance of the identification and packaging of the components, avoiding fraudulent or counterfeit materials in their manufacture, and ensuring delivery conditions, this point is included in the new industrialization procedure PSC-35, developed during 2021 and implemented in 2022.

In order to verify that adequate weight is being given to product preservation and control of fraudulent material, these have been specifically included as points to be checked within the Quality First audits carried out from September to December 2022.

In 2022, Aciturri hosted the 31st Aerospace Committee Meeting at its Miranda de Ebro facilities (Ircio and Ayuelas).

The activity of the Quality team with stakeholders in the aeronautical environment has been maintained, especially in the Spanish Quality Association (AEC), in which Aciturri is part of the governing body of the Aerospace Committee, after the elections held in 2022, in which the president has changed (currently, Ramón Mayor, from ADS) and the vice presidents are maintained. In 2022, Aciturri hosted the 31st Aerospace Committee Meeting at its Miranda de Ebro facilities (Ircio and Ayuelas), with the closing meeting being held at the Miranda Technology Center, Aciturri's partner for the process and test development.

Each year, the Quality area prepares the data for the Official Catalogue on the Spanish Defense Industry, which publishes the main data of the companies that have some kind of business with Defense and whose objective is to make known and promote the capabilities of the Spanish Defense Industry in foreign markets.

"Quality First" has motivated a change in people's mindset and in the way they approach problems.